CHAPTER 5

1 MARK

1. List the types of induction furnace.

Ans. Core type induction furnace 2) Coreless type induction furnace

2. List any four requirements of a good heating element.

Ans. Requirements of a good heating element are
a) High specific resistance, b) Low-temperature coefficient of resistance,
c) High melting point d) High mechanical strength e) Non-corrosive
f) Ductile g) Positive temperature coefficient of resistance h) Economical

3. Classify resistance heating.

Ans. Resistance heating is classified as
a) Direct resistance heating, b) Indirect resistance heating,
c) Infrared or radiant heating

4. List types of arc furnaces and their applications.

Ans. Applications of arc furnaces are
a) Direct arc furnace: To produce steel
b) Indirect arc furnace: Melting of non-ferrous metals

5. List the applications of seam welding.

Ans. 1) It is used for making lap and butt welds
2) It is employed for pressure tight and leak proof tanks such as transformer
tank, gasoline tanks, aircrafts and various types of containers.

6. Define induction heating.

Ans. It is defined as the process that makes use of currents induced by
electromagnetic action in the material to be heated.

7. Define electric welding.

Ans. Welding is defined as the process by which metals are joined together by
the application of heat and pressure.
 3 MARKS
1. List any six advantages of electric heating.
Ans.
The various advantages of electric heating are :
Cleanliness, no pollution , ease of control, uniform heating, high efficiency, low
attention, better working conditions, high temperature, less floor area is
required.

2. State the different types of electric welding.

Ans.

3. List any six industrial applications of dielectric heating.

Ans.
Applications of Di-electric heating :
 Drying tobacco, paper, wood and rayon
 welding of PVC
 stress annealing textile fibres
 heating of bones and tissues
 gluing and bonding of woods
 sterilization of cereals and medical equipment
 heat sealing of plastic sheets
 preparation of thermo plastic resins
4. Classify the various types of temperature control of resistance heating.
Ans.
Classification of temperature control of resistance heating;
a) By varying supply voltage:
1. By variable supply
2. By autotransformer
3.By series impedance

b) By varying the resistance of element:

1. By varying the number of heating elements
2. by changing the arrangement of heating elements.

c) Periodically switching on and off of the power supply

5. List the types of resistance heating and their applications.

Ans.
Applications of resistance heating are
Direct resistance heating
a) scrap heating b) resistance welding c) saltwater bath furnace d) in electrode
boiler for water heating etc

Indirect Heating
a) Immersion water heaters b) Room heaters c) In bi-metallic strips used in
starters

6. Draw the characteristics of a welding generator.

Ans.
7. List any six requirements of a good heating element.
Ans.
Requirements of a good heating element are
a) High specific resistance, b) Low-temperature coefficient of resistance,
c) High melting point d) High mechanical strength e) Non-corrosive
f) Ductile g) Positive temperature coefficient of resistance h) Economical

5 MARKS
1. Compare High frequency and Power frequency coreless induction furnaces
Ans.

2. Explain the advantages of electric heating.

Ans.
Advantages of electric heating are:
a) Cleanliness: Electric heating completely eliminates the dust and ash and it
keeps the surroundings cleanly.
b) No pollution: Due to the absence of flue gases, there is no risk of
contamination of the atmosphere.
c) Ease of control: It is possible to control and regulate the temperature
accurately either by manual or by fully automatically. This is not possible with
non- electric heating.
d) Uniform heating: The charge can be heated uniformly throughout whether
the charge is conducting or non- conducting material
e) High efficiency: The overall efficiency of electric heating is high since the heat
can be produced directly in the charge itself.

3. Explain the procedure of metal arc welding with a neat sketch

Ans.
In metallic arc welding, the electrode used must be of the same metal as that of
the workpiece to be welded. The electrode itself forms the filler metal. For metal
arc welding both a.c and d.c can be used. An arc is struck when the electrode
touches the workpiece and withdrawn apart. The high temperature of the arc
melts the little portion of the workpiece as well as the tip of the electrode. The
two pieces to be welded fuse together and when the electrode is removed the
workpiece cools and solidifies giving a strongly welded joint. The temperature
of the arc will be over 35000 𝐶. The short arc produces sound weld. The potential
difference across the arc is 20 to 25 volt., under any circumstances the voltage
should not exceed 30V, otherwise the welds made under these conditions will
not be sound. It is the most common type of arc welding and is normally
manually operated process. Therefore it is also referred to as manual metal arc
welding
4. Draw a neat sketch and explain the working principle of a welding generator.
Ans.
A differently compounded DC generator is used as a welding generator. The
generator is having a drooping characteristic. That means as the load current
increases, the demagnetization by differentially wound series field i.e shunt, and
series fields in opposition will increase which in turn will reduce the net flux per
pole and hence generated e.m.f. The reverse happens when the load current
decreases. In manual arc welding, it is impossible to keep the arc length
constant. Any change in arc length correspondingly changes the arc voltage also.
It is desirable to have a small current change for given changes in the arc voltage.
This is possible only if the voltage source is having a drooping characteristic as
shown in the figure. The steep volt-ampere characteristics is important from the
arc stability point of view and is possessed by a differentially compounded d.c
generator as shown in fig.
5. Compare resistance welding and arc welding in any five aspects.
Ans

6. Explain the procedure of spot welding with a neat sketch.

Ans. Spot welding is used for joining two or more sheets of metal by means of
an overlapping joint. The workpieces or plates to be welded are held between
two electrodes and pressed together by mechanical pressure exerted through
electrodes as shown in fig. Now the current is passed for a definite period of
time, depending upon the size of plates. The passage of current will generate
heat at the three junction faces, two between electrodes and workpieces, and
one between two workpieces. The heat produced between the workpieces
produces a spot weld. The unwanted heat generation between electrodes and
workpieces is to be avoided either by water-cooled electrodes or by making the
electrodes with high electrical and thermal conductivity so that the heat
developed is minimum.